Kawasaki ER5/KLE/EX500 - Episode 70 - Shifter Mechanism Install

In this episode I install the selector mechanism and fit the outer cover. I also show some microscope pictures of the rust damage that has eaten into the selector spline.

[@killerclown1740]

I love this series can't wait to see you take it for a ride .

[@dirtygarageguy]

Cheers dude - thanks for the comment - matt

[@martinowl]

I had an oil leak from that cover some time ago, it was lots of fun trying to remove the cover with the engine in the frame. Whist watching you putting it all back together, was talking to the screen saying 'that cover won't go back on like that'. It took me a few minutes to work it out that the shaft has to fitted to the cover before the cover can be refitted onto the engine.

[@dirtygarageguy]

We should get t-shirts made up lol

[@philno]

im glad to see im not the only person who swears at my bike, i have the gpz500, same shit different day

[@dirtygarageguy]

If it could, it would have divorced me by now.

[@philno]

i know this feeling of disdain well.... its the not speaking to me anymore that gets to me the most

[@forevercomputing]

3 weeks? That's quite quick. I waited over 2 months for a couple of specialist tools.

[@alenenger3349]

How did you get the link for your gear shift onto the shaft after you assembled it?

[@michaellucinda]

Great video. I have refitted mine - like you did - but it only takes neutral and first gear. Wont go up to 2nd etc. Any idea why?

[@dirtygarageguy]

You've fucked up the ball bearing in the output shaft

[@cringefrog4998]

⁠ What is the fix for that? Mine goes to second and stops there. Is it the bearing dropped a ball?

[@Broncko]

Thank you for this series! Where do you get your gaskets from?

[@dirtygarageguy]

Wemoto - www.wemoto.com/bikes/kawasaki/er-5_er_500_a2_a3_a4/98-00/ Just scoll down and find the Engine Gasket section. I ordered the Athena Italy set and it had everything - matt

[@jeffreyvangelderen3813]

Hi er-5 is looking good!! i have also a er-5 from 2003 but with a problem when i get on the highway my steer vibrates like a concrete drill when i get above 100 km and sometimes it is gone and then it is fucking back again😲 i have asked the kawasaki dealer and they say it is a 2 stroke thats why it vibrates but i think it is to much for comfort i want to go drive trough europe with it this bike this summer can you help me Kawasaki master😊

[@dirtygarageguy]

2 Stroke? Did you mean 4 stroke? To answer your question I have 2 questions 1 - do you have aftermarket handlebars? If you have stock are the bar weights still fitted or have you fitted those stupid bar mirrors? 2 - Have you checked the following? a - steering bearings b - your yoke nut and locking ring tightness? c - your engine mounts? d - your engine bolts? - matt

[@jeffreyvangelderen3813]

hi i meant by 2 stroke 2 cilinder engine and the handle bar is still the same and no stupid mirrors👍 i will check your problem list and let you know

[@1981dasimpson]

old video i know i have the en500 er5 engine just swapped engine to another as mine head gasket i think is gone so engine running i can not select first gear but i can select 2nd no problem any idea please if i need to do the selector arm im thinking of removing engine bolts and lifting the engine to get access just spent a week stripping the bike to fit another engine and then rebuild i tend to use grease to hold gaskets in place

[@dirtygarageguy]

Ah that could be the kawasaki neutral selector. It's a set of ball bearings in the gear shaft.

[@1981dasimpson]

@@dirtygarageguy it does neutral and 2nd but cant seem to get 1st or 3rd etc only engine running and wheeling a few fet back and forwed in shed going to drag her out tomorrow see if i can get all gears if not i think i may look at getting its engine sorted i think head gaskets are warped head

[@1981dasimpson]

@@dirtygarageguy if it is what do i do

[@1981dasimpson]

@@dirtygarageguy ok changed oil engine warm I can select 2nd and neutral no problem but try to select 1st or 3rd and lever solid wont move like it would to change gear

[@dirtygarageguy]

You might be missing a selector fork, or someone's put the wrong ones in the wrong location lol

[@planegaper]

think the silicone at top of the gasket is a kawi cheat to keep the gasket from moving about... bastards!!!